BODY BIKE Basic Instructions For Mechanics Manual

BODY BIKE ® I N DOOR CYCLE BODY BIKE Basic BODY BIKE Classic BODY BIKE Classic Stainless Steel B R A K E S Y S T E M L U B R I C A T I O N F R E E

Equipment required 2 Introduction 3 Specifi cations 4 General information 5 Warranty 5 Assembly Unpacking 7 Handlebar 8 Bottom frame 8 Saddle 9 Pedals 9 Maintenance Cleaning 11 Adjustment handle 12 Cleaning the posts 13 Poly-V belt 14 Replacing the brake block 15 Trouble-shooter 17 Index 17 EQUIPMENT REQUIRED Unpacking Drill bit Drill Bottom Frame 6 mm Allen wrench 13 mm wrench Saddle 14 mm wrench Pedals 15mm pedal wrench Grease Cleaning Tissue paper or cloth Spray bottle with water Soap (only washing-up liquid) Vaseline oil Post Cleaning Cloth Vaseline oil Adjustment Handle 5mm Allen Wrench Screwdriver Steel brush Grease Brush Poly-V Belt 10 mm Allen wrench 19 mm wrench Screwdriver Measuring device Brake block 8 mm wrench

maintenance of the BODY BIKE indoor cycle. The manual is intended for the owners and service people responsible for cleaning and maintenance. Before assembling the cycle, please read the manual and prepare the correct tools, see equipment required page 2. When assembling the cycle, we recommend that you follow the manual step by step. Maintaining the cycle is very important. In the manual you will fi nd clear instructions on how to maintain the cycle. Over time it will be necessary to replace worn-out parts. You will fi nd a detailed description and exploded drawings of BODY BIKE’s spare parts on our website www.body-bike. When ordering spare parts from the local BODY BIKE distributor, please refer to the item number (P/N no.) in order to make sure you will receive the correct spare part. We recommend that you order original parts, accessories and materials necessary for the maintenance of the cycle at your local BODY BIKE distributor. For further information on accessories, please check our website www.body-bike.com. 3 We wish you the best of luck with your BODY BIKE indoor cycle BODY BIKE ® I N DOOR CYCLE

Pier 6 Nord DK-9900 Frederikshavn Denmark Tlf: +45 9843 9696 Fax: +45 9843 9688 www.body-bike.com Product description: Indoor cycle Length, Width, Height: Assembled size: 105cm, 60cm, 100cm Packed size (5 cycles): 120cm, 80cm, 114cm Weight: Assembled: 65 kg Packed weight(5 cycles): 350 kg Patent held for: Crank system Maximum user weight 150 kg (Please note that the max. pedal load may be lower) Materials Basic version: Cast iron Steel and chrome Plastic (ABS) covers Quality bearings Frame: Robot-welded, powder coated and hardened Classic version: Cast iron Stainless steel Plastic (ABS) covers High quality bearings Frame: Robot-welded, fully galvanized, powder coated and hardened Classic Stainless Steel version: Cast iron Stainless steel Plastic (ABS) covers High quality bearings Frame: Robot-welded, stainless steel, electro galvanized.

WARRANTY A two-year warranty for the Danish manufactured BODY BIKE Indoor Cycle: A two-year warranty against manufacturing defects, excluding normal wear and tear, is given for the fl ywheel and pulley. A three- year warranty is given on the crank and the pedal arms, and a fi ve year warranty is given against frame breakage. Consumable items (such as the poly V-belt, brake pad, handlebar rubber, saddle and pedals, etc.) which are subject to continuous wear and tear, are not covered by a warranty. There is currently no warranty applying to the pedals. The warranty only applies to cycles equipped with original BODY BIKE spare parts. All warranties are cancelled if the cycle has been modifi ed or in any way not used as intended. GENERAL INFORMATION Wipe off the cycles after EVERY use ALWAYS loosen all handles and release tension after use The rubber feet should always be adjusted to ensure that the cycle is in level Every other year the rubber feet should be replaced as the rubber hardens and becomes unable to absorb the impact Tighten up the pedals every 14 days or every month to avoid them getting loose or breaking off. Pedals should be changed once a year DO NOT perform stretch exercises on the cycle, pedals or up against the cycle, except against the strech plate at the rear end of the cycle DO NOT switch the front or seat post from one cycle to another DO NOT lift the cycle by the saddle 5 ALWAYS RELEASE TENSION AFTER USE

UNPACKING THE PALLET 1) Begin with opening the top of the box. 2) Remove all the unmounted parts. 3) Flatten the box on the fl oor next to the pallet. 4) Loosen the two screws mounting the fi rst cycle to the pallet. 5) Lift the cycle off the pallet and place it on the fl attened box to spare your fl oor from getting marks. 7

tighten the nuts. They should only be hand tight. Figure 1 WASHER LIFT Figure 2 BOTTOM FRAME A fi xing tool can be bought at BODY BIKE International A/S to ease the mounting of the bottom frame. 1. Arrange the bottom frames parallel on the fl oor next to the cycle with the correct mounting distance between them, see fi gure 2. On the front bottom frame, the transport wheels should point forward. 2. Take hold of the front post and seat post and lift the cycle onto the bottom frames, see fi gure 2. Ensure that the holes in the frame match the holes in the bottom frames. 3: Put on the spring lock washer and the cap nut and tighten by using a 13 mm wrench, see fi gure 3. 4: Unscrew the rubber feet a little. Place the cycle in the correct position. Turn them up and down until the cycle stands properly and it is in level. HANDLEBAR 1: Place the handlebar on top of the front post. 2: Screw an adjustment handle (size 32mm) clockwise into the socket from underneath the post, see fi gure 1. Fix the handlebar completely to the front post by tightening the adjustment screw on the side of the handlebar. Figure 3

SADDLE 1: Place the saddle in the track on the seat post. 2: Secure the saddle with the remain- ing adjustment handle, see fi gure 4. To fasten the saddle to the adaptor and adjust the tilt of the saddle use a 14 mm wrench on the bolt marked with an A on fi gure 4. PEDALS 1: Place the right pedal arm with the socket pointing upwards, see fi gure 5. 2: Put maximum resistance on the brake, so the pedalarm is unable to rotate, see fi gure 6. Figure 7 9 Please note - the pedals are marked with R for Right and L for Left side. - the pedals should always be screwed on in the direction of the handlebar, see fi gure 7. - make sure that the hole in the pedal arm is greased when mounting the pedal. - start mounting the pedal by hand as tools will tighten the pedal at a wrong angle. Figure 6 Figure 5 Figure 4 WASHER A 3: After tightening by hand, use a 15mm pedal wrench to tighten the pedal completely (45N/4,5kg).

11 Adjustment handles (Every 3 months) 12 Cleaning the posts (Every other week) 13 Poly-V belt (When necessary) 14 Replacing the brake block (When necessary) 15 MAINTENANCE

with tissue paper. If the cycle is covered in sweat or dirt, use water in a spray bottle and if necessary a tissue with some washing-up liquid. Remember handlebar and saddle. NEVER use alcohol or chemicals To make the cycle look its best, use a cloth with a little vaseline oil on all parts except the handlebar and saddle. Always make sure that the small hole by the front bottom frame is not blocked and allows water and sweat to exit the frame, see fi gure 8. 11 SMALL HOLE Figure 8 BODY BIKE ® I N DOOR CYCLE

to protect the parts from sweat, dust, dirt and water. 1: Remove the adjustment handle and disassemble the handle completely into a screw, a spring, a handlegrip, a main screw and a brass washer, see fi gure 9. 2: Clean all the parts thoroughly one by one using a steel brush. If the residue is extreme, a sharp object can be used, for example a screwdriver. 3: Lubricate the internal parts with grease before Figure 9 reassembling the handle. Remember to lubricate inside the handle as well. 4: Reassemble the handle by inserting the main screw in the handle grip. 5: The spring is inserted into the top of the handle and fi xed in place with the remaining screw. 6: Tighten with a 5mm Allen wrench. 7: Add grease to the main screw before mounting it on the cycle. By pulling the handle it can be turned freely. Please note Never use a tool when tightening the adjustment handle on the cycle. SPRING HANDLEGRIP MAIN SCREW WASHER SCREW

13 CLEANING THE POSTS Every other week the posts need cleaning to protect them from sweat etc. 1: Pull out the seat post and the front post and wipe them clean with an oily cloth, see fi gure 10. If there is a slight sideways play in the front post you can adjust it on both sides of the cycle with the screws marked with an S on fi gure 10. This adjustment has to be very subtle in order for the post still to be able to move up and down. S Figure 10 Please note: The posts should be cleaned every other week to keep them in good condition

for it to be tightened. 1: Remove the service hatch on both sides of the cycle with a screwdriver, see fi gure 11. 2: Loosen the bolts (1) on both sides of the cycle with a 19 mm wrench, see fi gure 12 3: Loosen the nuts (2) on the counter bolt on both sides of the cycle with a 10 mm wrench, see fi gure 12. 4: Use a wrench to tighten the counter bolts (3). On the right side, the tool should be pulled downwards and on the left side upwards to tighten with a 10 mm wrench. 5: The belt should be tightened to approximately 125 kg/229 Hz. To measure this, a special device can be bought at your local BODY BIKE Distributor. SERVICE HATCH (1) (2) (3) Figure 11 Figure 12 Please note: The belt should be equally tightened on both sides. The fl ywheel should be parallel with the long main side member.

6: Tighten the counter bolt (2) on both sides of the cycle again. 7: And tighten the bolt(1) again on both sides of the cycle. 8: Close the cycle by fastening the two hatches again. REPLACING THE BRAKE BLOCK The BODY BIKE Synthetic Brake Pad has an expected durability of a minimum of 1500 hours, so eventually the brake pad will be worn. To ensure that the brake pad is correctly mounted, it has been pre-fi tted to the block, and it is only possible to purchase the complete brake block. To get to the brake block, it is necessary to remove the right side cover from the cycle. 1: Loosen all the screws in the side cover and remove them as well as the bottle holder. 2: Remove the side cover by placing the right pedal arm in the position of 7 o’clock. Then slide the side cover down and left over the pedal arm. 15 B R A K E S Y S T E M L U B R I C A T I O N F R E E

4: Remove the two screws holding the brake block to the frame by using an 8 mm wrench, see fi gure 13. 5: Take the new brake block and fasten it to the frame by tightening the screw closest to the brake block. Then place the block in the correct position under the brake, see fi gure 14. 6: Fasten the remaining screw furthest away from the block, and then make sure that both screws are tightened properly, see fi gure 15. 7: Grease should be applied to the cavity on top of the brake block or to the top nut on the brake to ensure a smooth interaction between the two. 8: Finally, remount the side cover by screwing in the corner screws fi rst. Hereafter the remaining screws. Figure 14 REMOVE Figure 13 Figure 15

It is a good idea to place a board at the exit of the spinning room displaying all cycle numbers. Here people can write possible problems or concerns arisen during the exercise. In this way, the people who are servicing the cycles can get up-dated regularly on how the cycles are performing, and problems can be identifi ed before they turn critical. Adjustment handles 12 Adjustment screw 8, 13 Assembly 7- 9 Belt 14 Bottom frame 5, 8 Brake 15 Cleaning 11-13 Cover 15 Crank, warranty 5 Frame 8 Grease 12 Handle 8, 9,12 Handlebar 8 Height 4 Information, general 5 Length 4 Maintenance 11-16 Manufacturer 4 Mounting 7-9 Patent 4 Pedal 9 Poly V-belt 14,15 Post (front and seat) 13 Product description 4 Rubber feet 5, 8 Saddle 9 Side cover 15 Tools 2 Trouble shooter 17 User weight 4 Wear and tear 5, 17 Weight 4 Width 4 Wheel 8 INDEX 17 BODY BIKE ® I N DOOR CYCLE

Including a range of spare parts for easy replacement of wear and tear parts. Item number: 97200000

Handy tool box containing a wide range of tools for maintenance purposes, e.g. the three spanners included in the starter set. Item number: 92300000 Find spare parts and accessories on our webpage. www.body-bike.com BODY BIKE ® I N DOOR CYCLE

Pier 6 Nord DK-9900 Frederikshavn Denmark Tlf: +45 9843 9696 Fax: +45 9843 9688 www.body-bike.com BODY BIKE ® I N DOOR CYCLE Edition 4